Laminate webs and absorbent articles having the same

ABSTRACT

A laminate web having a polymer film layer and a nonwoven layer is disclosed. The polymer film layer makes up a first side of the laminate web and the nonwoven layer makes up a second side of the laminate web. The laminate web has a plurality of first elements extending from the polymer film. The web also has a plurality of second elements such as recesses, protrusions, apertures, embossing and combinations thereof.

FIELD OF THE INVENTION

The present invention is directed to laminate webs comprising a polymerfilm having microtextures and a nonwoven, and absorbent articlescomprising the laminate web.

BACKGROUND OF THE INVENTION

Laminates of webs such as films and fibrous webs are known in the art.For example, nonwoven webs are often laminated with polymer films suchthat they are useful as materials in disposable products such astopsheets on disposable absorbent articles. The laminate can bestructured such that a skin-facing side of the laminate, when used inabsorbent articles, is the polymer film. The laminate also can bestructured in absorbent articles such that the polymer film is orientedas a garment-facing side. Polymer film is desirable to have amicrotextured, preferably apertured three-dimensional surface which canprovide the surface of the laminate web with a desirable feel (e.g.,soft, silky), visual impression, and/or audible impression, as well asone or more desirable properties such as improved fluid handling.

Webs exhibiting a desirable feel can be made by forming microtexturessuch as protrusions and recesses in the webs via technologies such as avacuum forming process and embossing process.

Laminate webs having a microtextured film are utilized in a wide varietyof industrial and consumer products. Such laminate webs are known foruse in disposable absorbent articles such as disposable diapers andfeminine hygiene articles such as sanitary napkins, and the like. Sucharticles typically have a fluid pervious topsheet, a fluid imperviousbreathable backsheet, and optionally an absorbent core disposed betweenthe topsheet and the backsheet. Laminate webs having a microtexturedfilm layer and a nonwoven layer can be made to form a fluid pervioustopsheet that transports fluid from the body facing surface of thesanitary napkin more deeply into the sanitary napkin or diaper towardsthe absorbent core.

Laminate webs comprising a microtextured polymer film layer can befurther deformed to have two-dimensional or three-dimensional macrostructures improving fluid transport such as apertures for improvingfluid drainage.

One approach as an effort to improve the ability of fluid drainage in alaminate having a film layer and nonwoven web is to expose fibersextended from the nonwoven web. U.S. Pat. No. 8,273,943 discloses anabsorbent article provided with a composite sheet which comprises a filmsheet having multiple pores formed therein a fiber mass laminated on oneside of the film sheet, wherein the fiber mass has a projected sectionin which a part of the fiber mass projects through the multiple porestoward the other side of the film sheet. WO2010/117636 discloses alaminate web having a nonwoven web and a microtextured polymer film,wherein the laminate web has a first side comprising the polymer filmhaving caps and tufts including fibers extending from the nonwoven web.Each of the caps is an integral extension of the polymer film and havingat least one opening including a location of rupture in the polymer filmabove which the tuft extends. The exposed fibers extended from nonwovenweb acquire and retain some fluid in small capillaries that might existbetween the fibers which may be visually perceptible to the user of theproduct as an undesirable stain.

However, even with formation of macro apertures for improving fluidtransport in a microtextured web, there still is a challenge in fluiddrainage especially when the polymer film layer has microprotrusions, asfluid tends to be trapped in valleys between the microprotrusions.Especially when microtextures are in the form of discrete extendedelements like protrusions, in case the microtextured web is used as atopsheet of absorbent articles, fluid tends to be trapped in valleysamong the discrete extended elements. Trapped fluid may be visuallyperceptible to the user of the product and the user may misinterpret thestaining as an indication that the utility of the product is exhaustedeven when such a determination is in reality premature.

Meanwhile, post-formation of macrostructures on a microtextured laminatemay do damage on microtextures such as microprotrusions on the surfaceof the laminate which may deteriorate surface smoothness or negativelyaffect fluid transport as embossing sites is embossed at the zero planeof the laminate and is flatted.

Meanwhile, U.S. Pat. No. 5,643,240 discloses a body side liner forabsorbent articles comprising an aperture film layer and a separationlayer comprising lofty fibrous nonwoven suited for use as a covermaterial which provides an improved fluid penetration rate, andmitigated rewet by reducing flow-back to the surface of the absorbentarticle. U.S. Pat. No. 7,695,799 discloses a perforated laminate usefulas a topsheet for absorbent articles that comprises first and secondlayers and perforated apertures that extend through at least the firstlayer wherein the first layer is a nonwoven that has filaments fromabout 0.2 to about 15 dpf, or a formed film having a basis weight fromabout 15 to about 50 gsm, and the second layer comprises a fibrousnonwoven absorbent structure having a median wet pore diameter betweenabout 3 μm and about 50 μm.

Therefore, a need exists for a laminate web providing enhanced fluiddrainage and softness.

Therefore, another need exists for a laminate web providing improvedmasking of stain.

SUMMARY OF THE INVENTION

Disclosed herein is a laminate web comprising a polymer film layer, anonwoven layer, a first side comprising the polymer film and a secondside comprising the nonwoven layer. The laminate web comprises a) aplurality of first elements extending from the polymer film, b) aplurality of second elements which are protrusions extended from thefirst side of the laminate web, and c) a land area comprising at leastone first element which surrounding a majority of the protrusions. Eachof the protrusions has a protrusion base in the same plane of the firstside of the laminate web, and a majority of the protrusions have nomaterial break such as rupture and tearing of the polymer film betweentwo adjacent first elements at least at the protrusion base.

In addition, disclosed herein is a laminate web comprising amicrotextured polymer film layer, a nonwoven layer, a first sidecomprising the polymer film and a second side comprising the nonwovenlayer. The laminate web comprises a) a plurality of first elementsextending from the polymer film, b) a plurality of second elements whichare recesses downwardly extended from the first side of the laminateweb, and c) a land area comprising at least one first element. Therecesses may extend below the second side of the laminate web, so that abottom area of each of the recesses is below the second side of thelaminate web.

In addition, disclosed herein is a laminate web comprising a polymerfilm layer, a nonwoven layer, a first side comprising the polymer filmand a second side comprising the nonwoven layer. The laminate webcomprises a) a plurality of first elements extending from the polymerfilm, b) a plurality of second elements, each of the second elementscomprising at least one first element, and c) a land area comprising atleast one first element and surrounding at least some of the secondelements, wherein at least two adjacent second elements, respectively,have one or more than one first element having an open distal end atleast 1.5 times larger than the largest distal open end of a firstelement located in a land between the two adjacent second elements.

In addition, disclosed herein is a laminate web comprising a polymerfilm layer comprising polymer film, and a nonwoven layer comprisingnonwoven web, a first side comprising the polymer film and a second sidecomprising the nonwoven web, wherein the laminate web further comprisesa plurality of first elements, and wherein the nonwoven web comprises amedian distance between two adjacent fibers in a z-direction of aboveabout 55 μm.

In addition, disclosed herein is an absorbent article comprising atopsheet comprising the laminate web of the present invention, a liquidimpervious backsheet and optionally an absorbent core disposed betweenthe topsheet and the backsheet.

Disclosed herein is also a process for producing the laminate web of thepresent invention comprising the steps of forming a precursor laminateweb comprising a polymeric film layer comprising film and a nonwovenlayer, forming a plurality of first elements extending from a firstsurface of the film layer in the z direction by a vacuum formationprocess, forming a plurality of second elements, and heat-setting thesecond elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross section view of a laminate web suitable forthe present invention.

FIG. 2A is a schematic perspective view of a laminate web havingprotrusions according to the present invention.

FIG. 2B is an enlarged cross-sectional view of section 2A-2A of FIG. 2A.

FIG. 3 is a plan view of an enlarged portion of the laminate web havinga protrusion shown in FIG. 2A.

FIG. 4A is a schematic perspective view of a laminate web havingrecesses according to the present invention.

FIG. 4B is an enlarged cross-sectional view of section 4B-4B of FIG. 4A.

FIG. 5 is a schematic representation of a process for forming a laminateweb of the present invention.

FIG. 6A is a schematic representation of a process for forming anotherlaminate web of the present invention.

FIG. 6B is a schematic representation of a process for forming anotherlaminate web of the present invention.

FIG. 7 is a cross-sectional representation of a portion of a secondelement forming unit forming a laminate web of the present invention.

FIG. 8 is a schematic representation of an exemplary tooth for a secondelement forming unit for producing one embodiment of laminate webs ofthe present invention.

FIG. 9 is a schematic representation of another exemplary tooth for asecond element forming unit forming another embodiment of laminate websof the present invention.

FIG. 10 is a schematic representation of a configuration of teeth in asecond element forming unit for producing a laminate web of the presentinvention.

FIG. 11A is a view of intermeshing engagement of a portion of a secondelement forming unit for producing one embodiment of laminate webs ofthe present invention.

FIG. 11B is a view of a portion of a first member of a second elementforming unit in FIG. 11A.

FIG. 11C is a view of a portion of a second member of a second elementforming unit in FIG. 11A.

FIG. 12 is a view of intermeshing engagement of a portion of a secondelement forming unit forming a laminate web of another embodiment of thepresent invention.

FIG. 13A is a plan view of a film side scanning electron microscopeimage of a laminate web having protrusions according to the presentinvention.

FIG. 13B is a plan view of a nonwoven side scanning electron microscopeimage of the laminate web of FIG. 13A.

FIG. 14A is a plan view of a film side scanning electron microscopeimage of a laminate web having protrusions according to the presentinvention.

FIGS. 14B-14D are plan views of higher magnitude scanning electronmicroscope images of the laminate web of FIG. 14A.

FIG. 15A is a plan view of a nonwoven side scanning electron microscopeimage of a laminate web having recesses according to the presentinvention.

FIG. 15B is a plan view of a film side scanning electron microscopeimage of the laminate web of FIG. 15A.

FIG. 16 is a plan view of a microscopic image of a cross section in thewidth direction of recesses of the laminate web of FIG. 15A.

FIG. 17A is a plan view of a nonwoven side scanning electron microscopeimage of a laminate web having recesses according to the presentinvention.

FIGS. 17B-17D are plan views of higher magnitude scanning electronmicroscope images of the laminate web of FIG. 17A.

FIG. 18A is a plan view of a film side light microscope image of alaminate topsheet of a commercially available sanitary napkin.

FIG. 18B is a plan view of a microscopic image of a cross section of theweb of FIG. 18A.

FIG. 19 is a microscopic image in a film side of a laminate web ofanother embodiment according to the present invention.

FIG. 20 is a microscopic image of a film layer of a laminate.

FIG. 21A is a perspective view of a strikethrough plate for acquisitiontime measurement.

FIG. 21B is a plan view of the strikethrough plate of FIG. 21A.

FIG. 21C is a plan view of a 21C-21C direction cross section of thestrikethrough plate of FIG. 21B.

FIG. 21D is a plan view of part pf the strikethrough plate of FIG. 21B.

FIG. 21E is a plan view of a 21E-21E direction cross section of thestrikethrough plate of FIG. 21B.

FIG. 22 is a plan view microscopic image of a sanitary napkin accordingto the Stain Perception Measurement.

FIG. 23 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 24 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 25 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 26 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 27 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 28 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 29 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 30 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 31 is a plan view microscopic image of a commercially availablesanitary napkin according to the Stain Perception Measurement.

FIG. 32 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

FIG. 33 is a plan view microscopic image of another sanitary napkinaccording to the Stain Perception Measurement.

DETAILED DESCRIPTION OF THE INVENTION

The term “absorbent article” includes disposable articles such assanitary napkins, panty liners, tampons, interlabial devices, wounddressings, diapers, adult incontinence articles, wipes, and the like. Atleast some of such absorbent articles are intended for the absorption ofbody liquids, such as menses or blood, vaginal discharges, urine, andfeces. Wipes may be used to absorb body liquids, or may be used forother purposes, such as for cleaning surfaces. Various absorbentarticles described above will typically comprise a liquid pervioustopsheet, a liquid impervious backsheet joined to the topsheet, and anabsorbent core between the topsheet and backsheet.

The term “absorbent core”, as used herein, refers to the component ofthe absorbent article that is primarily responsible for storing liquids.As such, the absorbent core typically does not include the topsheet orbacksheet of the absorbent article.

The term “adjacent”, as used herein, with reference to features orregions, means near or close to, and implies an absence of anything ofthe same kind in between the features or regions.

The term “aperture”, as used herein, refers to a hole. The apertures caneither be punched cleanly through the web so that the materialsurrounding the aperture lies in the same plane as the web prior to theformation of the aperture (a “two dimensional” aperture), or holesformed in which at least some of the material surrounding the opening ispushed out of the plane of the web. In the latter case, the aperturesmay resemble a protrusion or depression with an aperture therein, andmay be referred to herein as a “three dimensional” aperture, a subset ofapertures.

The term “component” of an absorbent article, as used herein, refers toan individual constituent of an absorbent article, such as a topsheet,acquisition layer, liquid handling layer, absorbent core or layers ofabsorbent cores, backsheets, and barriers such as barrier layers andbarrier cuffs.

The term “cross-machine direction” or “CD”, as used herein, refers tothe path that is perpendicular to the machine direction in the plane ofthe web.

The term “deformable” material, as used herein, is a material which iscapable of changing its shape or density in response to applied stressesor strains.

The term “discrete”, as used herein, means distinct or unconnected. Whenthe term “discrete” is used relative to forming elements on a formingmember such as a roll, plate and belt it is meant that the distal (orradially outwardmost) ends of the forming elements are distinct orunconnected in all directions, including in the machine andcross-machine directions (even though bases of the forming elements maybe formed into the same surface of a roll, for example).

The term “forming elements”, as used herein, refers to any elements onthe surface of a forming member such as a roll, plate and belt that arecapable of deforming a web.

The term “layer” used herein should be understood that the term “layer”is not necessarily limited to single layers or sheets of material. Thus,the layer can comprise laminates or combinations of several sheets orwebs of the requisite type of materials. Accordingly, the term “layer”includes the terms “layers” and “layered”.

The term “machine direction” or “MD”, as used herein, refers to the paththat material, such as a web, follows through a manufacturing process.

The term “macroscopic” or “macro”, as used herein, refers to structuralfeatures or elements that are readily visible and distinctly discernableto a human having 20/20 vision when the perpendicular distance betweenthe viewer's eye and the web is about 12 inches (30 cm). Conversely, theterm “microscopic” or “micro” refers to such features that are notreadily visible and distinctly discernable under such conditions.

The terms “mechanical deformation”, as used herein, refers to processesin which a mechanical force is exerted upon a material to formtwo-dimensional or three-dimensional structures on a web.

The term “surrounded” or “surrounding”, as used herein, refers to bothbeing completely and continuously surrounded, and being discontinuouslysurrounded by other regions and/or apertures.

Laminate Web

Referring to FIG. 1, a laminate web 1 of the present invention,hereinafter referred to simply as web 1, comprises a nonwoven layer 20comprising nonwoven web and a polymer film layer 21 comprising polymerfilm. The nonwoven layer 20 has a first surface 12 and a second surface14, and film layer 21 has a first surface 13 and a second surface 15.Web 1 has a machine direction (MD) and a cross machine direction (CD) asis commonly known in the art of web manufacturing. The layers arereferred to herein as generally planar, two-dimensional webs. Thenonwoven layers 20 and the film layer 21 (and any additional layer) canbe joined by adhesive, thermal bonding, ultrasonic bonding and the like.Fibrous nonwoven web and film can be joined by applying the nonwoven webonto an extruded film while the film is extruded and still molten, andat least some fibers from the nonwoven web adhering to the molten film.As disclosed below, the constituent layers of web 1 can be joined byinterlocking mechanical engagement resulting from the formation ofsecond elements such as protrusions, recesses, embossing, and anycombinations thereof.

Web 1 has a first side 3 and a second side 5. The term “sides” is usedin the common usage of generally planar two-dimensional webs, such aspaper and films that have two sides when in a generally flat condition.In web 1 having elements, two surfaces in a flat land area may beconsidered the first side and the second side, respectively, that is, asurface in the land area in the film layer side is a first side and asurface in the land area in the nonwoven layer is a second side.

The nonwoven layer and film layer in the laminate of the presentinvention can have an opacity, and the second elements can be opaquewhich is preferable for masking of the color of the absorbed fluid. Toprovide appropriate level of opacity, the nonwoven layer may contain awhitener such as TiO₂ no less than 1% by weight of the nonwoven layer.The film layer may contain a whitener such as TiO₂ no less than 5% byweight of the film layer. In one embodiment, the film layer contains ahigher level of whitener than the nonwoven layer.

Nonwoven Layer

A laminate web of the present invention comprises a nonwoven layercomprising nonwoven web.

As used herein, the term “nonwoven web” refers to a web having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. Nonwoven webs or fabrics havebeen formed from many processes, such as, for example, meltblowingprocesses, spunbonding processes, hydroentangling, airlaying, and bondedcarded web processes, including carded thermal bonding and air-throughbonding. The basis weight of nonwoven fabrics is usually expressed ingrams per square meter (gsm). The basis weight of the laminate web isthe combined basis weight of the constituent layers and any other addedcomponents. Fiber diameters are usually expressed in microns (μm); fibersize can also be expressed in denier, which is a unit of weight perlength of fiber. The basis weight of laminate webs suitable for use inthe present invention can range from 10 gsm to 500 gsm, depending on theultimate use of the laminate web according to the present invention.

The constituent fibers of the nonwoven web can be comprised of polymerssuch as polyethylene, polypropylene, polyester, and blends thereof. Thefibers can comprise cellulose, rayon, cotton, or other natural materialsor blends of polymer and natural materials. The fibers can also comprisea super absorbent material such as polyacrylate or any combination ofsuitable materials. The fibers can be monocomponent, bicomponent, and/orbiconstituent, non-round (e.g., protrusionillary channel fibers), andcan have major cross-sectional dimensions (e.g., diameter for roundfibers) ranging from 0.1-500 μm. The constituent fibers of the nonwovenprecursor web may also be a mixture of different fiber types, differingin such features as chemistry (e.g. polyethylene and polypropylene),components (mono- and bi-), denier (micro denier and >20 denier), shape(i.e. protrusionillary and round) and the like. The constituent fiberscan range from about 0.1 denier to about 400 denier.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as for example, block, graft,random and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. In addition, unless otherwise specificallylimited, the term “polymer” includes all possible geometricconfigurations of the material. The configurations include, but are notlimited to, isotactic, atactic, syndiotactic, and random symmetries.

As used herein, the term “monocomponent” fiber refers to a fiber formedfrom one or more extruders using only one polymer. This is not meant toexclude fibers formed from one polymer to which small amounts ofadditives have been added for coloration, antistatic properties,lubrication, hydrophilicity, etc. These additives, for example titaniumdioxide for coloration, are generally present in an amount less thanabout 5 weight percent and more typically about 2 weight percent.

As used herein, the term “bicomponent fibers” refers to fibers whichhave been formed from at least two different polymers extruded fromseparate extruders but spun together to form one fiber. Bicomponentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebicomponent fibers and extend continuously along the length of thebicomponent fibers. The configuration of such a bicomponent fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement.

As used herein, the term “biconstituent fibers” refers to fibers whichhave been formed from at least two polymers extruded from the sameextruder as a blend. Biconstituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the cross-sectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibrils which start and end at random.Biconstituent fibers are sometimes also referred to as multiconstituentfibers.

As used herein, the term “non-round fibers” describes fibers having anon-round cross-section, and includes “shaped fibers” and“protrusionillary channel fibers.” Such fibers can be solid or hollow,and they can be tri-lobal, delta-shaped, and are preferably fibershaving protrusionillary channels on their outer surfaces. Theprotrusionillary channels can be of various cross-sectional shapes suchas “U-shaped”, “H-shaped”, “C-shaped” and “V-shaped”.

A nonwoven layer may comprise fibers having sufficient elongationproperties to have portions elongated. The portion elongated are formedby urging fibers out-of-plane in the Z-direction at discrete, localized,portions of the nonwoven layer. The urging out-of-plane can be due tofiber displacement, i.e., the fibers are able to move relative to otherfibers and be “pulled,” so to speak, out-of-plane. More often, however,for most nonwoven layers suitable for the laminate according to thepresent invention, the urging out-of-plane is due to the fibers havingbeen at least partially plastically stretched and permanently deformed.

The nonwoven layer useful for the laminate web according to the presentinvention can comprise a nonwoven web comprised of substantiallyrandomly oriented fibers. By “substantially randomly oriented” is meantthat, due to processing conditions for producing the precursor nonwovenweb, there may be a higher amount of fibers oriented in the MD than theCD, or vice-versa.

The nonwoven layer may have a basis weight of between and about 60 gsm,between about 12 gsm and about 25 gsm, or between about 12 gsm and about18 gsm. In general, nonwoven, especially spunbond nonwoven, of higherbasis weight reduces an acquisition speed though it may increase stainmasking.

In one embodiment of the present invention, the nonwoven layer comprisesa median distance between two adjacent fibers in a z-direction of aboveabout 55 μm, or in the range of about 60 to about 200 μm, when measuredaccording to the Fiber-Fiber Distance Measurement described in thepresent specification. When the nonwoven layer comprises cardednonwoven, the carded nonwoven can be produced to have a median distancebetween two adjacent fibers in a z-direction of above about 55 μm byoptimizing production conditions such as oven air flow temperature, hotair pressure, and nonwoven web tension when the web goes through theoven and/or calendar rolls in order to increase a caliper of thenonwoven. For example, the higher oven air flow temperature, the lowercaliper of the nonwoven, and the higher hot air pressure, the lowercaliper for the nonwoven. In addition, a tighter web tension may resultin a lower caliper of the nonwoven. In one example, the nonwoven web iscarded nonwoven formed from a polymer having a fiber thickness of noless than 5 denier.

Film Layer

A laminate web of the present invention comprises a film layercomprising polymer film. The polymer film comprises a plurality of firstelements.

Polymer film having first elements can be provided using any processknown in the art. Polymer film with first elements will provide theexterior surfaces of the web with a softer, more cloth-like texture,provide the web with a more cloth-like appearance, and increase theoverall caliper of the web. Examples of process forming first elementsinclude but are not limited to the following: mechanical deformation,flocking, ultrasonics, delamination of viscous melts from poroussurfaces, brushing, and any combination thereof.

The film layer may have a basis weight of between about 8 gsm to about35 gsm, between about 10 gsm to about 20 gsm, or between about 10 gsm toabout 14 gsm. Or, the film layer may have a basis weight of betweenabout 8 gsm to about 20 gsm, between about 10 gsm to about 18 gsm, orbetween about 12 gsm to about 15 gsm. If the second precursor web has abasis weight more than 20 gsm, desirable softness of laminates may notbe obtained. If the film has a basis weight less than 8 gsm, it may tearduring wearing of absorbent articles having the laminate of the presentinvention.

The film layer may have sufficient integrity to be formed into thelaminate web by the process especially when the laminate web has secondelements in addition to first elements. It may have sufficiently highelongation properties such as stretchability relative to nonwoven layerat a process temperature, especially at the temperature in a protrusionforming step described in detail below, such that upon experiencing thestrain of fibers from the nonwoven layer being urged out-of-plane in thedirection of the film layer, the film layer does not break or rupture,e.g., by tearing due to extensional failure, so that a majority of thesecond elements have no material break between two adjacent firstelements described in detail below.

First Elements

The laminate web according to the present invention comprises aplurality of first elements extending from the polymer film. The firstelements may have open proximal ends, open or closed distal ends, andsidewalls. The first elements may extend outwardly from the first sideof the laminate web. Without being bound by theory, it is believed thefirst elements extended upwardly from the polymer film provide softnessand overall comfort to the skin when a film layer from which the firstelements extend is skin-facing layer in absorbent articles as it maylimit the film with protrusions directly contact the skin.

The first elements provide microtexture to the laminate web. The firstelements can, for example, be microapertures or micro bubbles, examplesof which are disclosed in U.S. Pat. No. 7,454,732, issued to Stone etal. and U.S. Pat. No. 4,839,216 issued to Curro et al., U.S. Pat. No.4,609,518 issued to Curro et al. As an example, the first elements canbe micro-apertures, the apertures have an area of between about 0.01 mm²and about 0.78 mm².

The first elements can also be apertured protrusions, non-aperturedprotrusions or fibrils to provide texture that provides for a tactileimpression of softness. Softness is beneficial when webs are used astopsheets in disposable absorbent articles. Referring to FIGS. 13A,14A-14D and 17A-17D, the web 1 according to the present invention iseffective in preserving first elements 4 even when the second elements 7are formed on precursor webs having the first elements 4.

In one embodiment, the first elements are discrete extended elementshaving a diameter shorter than a minor axis of protrusions formed in theweb of the present invention. In one non-limiting embodiment, thediscrete extended elements have a diameter of less than about 500microns; the discrete extended elements have an aspect ratio of at leastabout 0.2; and/or the web comprises at least about 95 discrete extendedelements per square centimeter. References disclosing such a pluralityof discrete extended elements include WO 01/76842; WO 10/104996; WO10/105122; WO 10/105124 and US20120277701A1.

In embodiments when the first elements are discrete extended elementswith open ends, the discrete extended elements may be formed by applyinghigh pressure vacuum against the forming surface of the forming memberthat the formed web ply is against. Such methods of aperturing are knownas “Vacuum Forming” and are described in greater detail in U.S. Pat. No.4,463,045. Examples of mechanical deformation is disclosed in U.S. Pat.Nos. 4,798,604, 4,780,352, 3,566,726, 4,634,440, WO 97/40793, andEuropean Patent 525,676. Examples of flocking are disclosed in WO98/42289, WO 98/36721, and European Patent 861,646. Examples ofultrasonics are disclosed in U.S. Pat. No. 5,269,981. Examples ofdelamination of viscous melts are disclosed in U.S. Pat. No. 3,967,623,and WO 99/06623. Examples of printed hair are disclosed in U.S. Pat. No.5,670,110. Examples of brushing are disclosed in WO 99/06623.

Second Elements

A laminate web according to the present invention may comprise aplurality of second elements. The second elements are macro features,and may be selected from the group consisting of protrusions, embosses,recesses, apertures and combinations thereof. The second elementpreferably comprises an arched side wall. The second element be amacroscopic structure.

Second elements are discrete, and may be of any suitable configuration.Suitable configurations for second elements include, but are not limitedto, features having plan view configurations including circular, oval,hour-glass shaped, star shaped, polygonal and the like, and combinationsthereof. “Polygonal” herein intends to include polygonal with roundedcorners. Polygonal shapes include, but are not limited to triangular,quadrilateral, hexagonal, octagonal or trapezoidal. The second elementsmay be arranged in a staggered pattern. In one embodiment, the secondelements have a plan view substantially quadrilateral such asrectangular, square, and lozenge shape. Lozenge shaped second elementsare preferred in a staggered array as the shapes can be well nested andminimize land area 8 between adjacent second elements.

The second elements may have a major axis and a minor axis perpendicularto the major axis. In one embodiment, the major axis of the secondelements is substantially parallel to the MD of a laminate web 1 of thepresent invention. In another embodiment, the major axis of the secondelements is substantially parallel to the CD of the web 1. In anotherembodiment, the major axis of the second elements is oriented at anangle relative to the MD of the web 1. Despite the terms of ‘major” and“minor” axes, it is intended that a major axis and a minor axis can havean identical length.

The plan view area of an individual second element, in some embodimentsof the laminate web of the present invention, may be greater than orequal to about 0.25 mm², 0.5 mm², 1 mm², 5 mm², 10 mm², or 15 mm². Thenumber of second elements per unit area of the laminate web of thepresent invention, i.e., the density of second elements, can be variedfrom about 5-60 second elements/cm². In one embodiment, the laminate webmay comprise second elements with a second element density of from about5 to about 60, or from about 10 to about 50, or from about 20 to about40 second elements/cm² web. There can be at least 20 second elements/cm²web, depending on the end use of the web. In general, the second elementdensity need not be uniform across the entire area of the laminate webof the present invention, but the second elements can be only in certainregions of the web, such as in regions having predetermined shapes.

The extension of polymer film in the second elements can be accompaniedby stretch of the film and a general reduction in thickness of the film.The stretch and reduction in thickness of the film may result inimprovement of fluid handling as open distal ends of the first elementsare enlarged, and improvement of softness as thinned film has reducedmodulus properties which provide the perception of softness to the userswhen touching the laminate web.

Referring to FIGS. 2A and 2B showing second elements 7, protrusions 7Pin this case, and FIGS. 4A and 4B showing second elements 7, recesses 7Rin this case, second elements 7 may be integral extensions of thepolymer film 21. As used herein, the term “integral” as in “integralextension” when used for second elements such as protrusions andrecesses refers to the substrate forming the protrusion havingoriginated from the polymer film. Therefore, the second element can be aplastically deformed elongated substrate of the polymer film, and is,therefore, integral with the polymer film.

Referring to FIG. 3, second element 7 can have a length and a width. Thelength of second element 7 is a length in a major axis of the secondelement 7. Second element 7 can also have a width taken to be themaximum dimension of the second element 7 as measured orthogonal to thelength 61 of the second element 7.

Referring to FIGS. 2B and 4B, the second element 7 can have a base 71 inthe same plane of the first side of the laminate web 1. The secondelement 7 integrally extends from the base 71. The base 71 can be widerthan a vertical cross section of the second element 7 away from the base71. That is, a width or a length of the base 71 can be longer than awidth or a length in a cross-section of the second element 7 away (i.e.above or below) from the base 71.

Second elements 7 in the web 1 may enhance fluid drainage. Without beingbound by theory, it is believed that fluid drainage may be improved viathe arching or sloped side wall in the second elements and a very smallarea of plateau on the top (when the second elements are protrusions) orthe bottom area 10 (when the second elements are recesses or embosses)in the 3-dimensional structure of the second element 7.

Enhanced drainage may result in reducing perceivable stain on the topside of absorbent article product having a topsheet comprising thelaminate web of the present invention. Stain reduction may help usersavoid determining to prematurely replace absorbent article products.Moreover, it provides perceived clean and dry topsheet as well asperceived good absorbent performance.

If the polymer film comprises a whitener such as titanium dioxide, thesecond elements 7 can be more effective at obscuring materials. Suchsecond elements 7 can better maintain a perceived color of white, whichmany consumers associate with cleanliness.

Polymer film layer 21 can have a polymer film thickness t and the secondelement 7 can have a second element thickness pt. Being that the secondelements 7 are integral extensions of the polymer film layer 21 andformed by stretching the polymer film out of plane of the first side 3of the web 1, the second element thickness pt of a portion of the secondelement 7 can be less than the polymer film thickness t. That is, thepolymer film that is elongated to form a second element 7 is thinned atleast some portion of the second element 7 relative to the planarportion of the polymer film from which the second element 7 extends. Thesecond element thickness pt at a distal portion of the second element 7may be about the same or less than the polymer film thickness t and thesecond element thickness pt at a portion of the second element 7 betweenthe distal portion of the second element 7 and the polymer film may beless than the polymer film thickness t. Thinning of the second element 7may provide for second element 7 having a soft feel to the skin. Secondelement 7, as the polymer film is stretched, has at least one firstelement having an enlarged open distal end which results in faster fluidacquisition. By stating of one first element having an enlarged opendistal end, it intends to mean that the first element has an open distalend which is larger than an original open distal end.

Second elements 7 may not have break or rupture, e.g., by tearing due toextensional failure of the polymer film, so that majority of secondelements 7 may have no material break between two adjacent firstelements, especially in a base 71.

The first and/or second precursor webs can have an opacity, and thesecond elements can be opaque which is preferable for masking of thecolor of the absorbed fluid. To provide appropriate level of opacity,the nonwoven layer 20 may contain a whitener such as TiO₂ no less than1% by weight of the nonwoven layer 20. The polymer film layer 21 maycontain a whitener such as TiO₂ no less than 5% by weight of the polymerlayer 21. In one embodiment, the polymer film layer 21 contains a higherlevel of whitener than the nonwoven layer 20.

The second element 7 comprises one or more than one first element 4. Atleast some of the second elements may have first elements havingstretched and enlarged distal open ends.

In some embodiments, at least one first element 4 in the second elements7 has an open distal end larger than at least one first element 4 in anadjacent land area 8. As used herein, the term an “adjacent land area”refers to a land area located between two adjacent recesses. Therefore,by stating that at least one first element 4 in the second element 7 hasan open distal end larger than at least one first element 4 in anadjacent land area 8, it intends to mean that at least one first element4 in one second element 7 has an open distal end larger than at leastone first element 4 in a land area located between the second element 7and another second element 7 adjacent to the second element 7. Referringto FIGS. 13A, 14A-14D, and 17A-17D, the web 1 of the present inventionmay comprise at least two adjacent second elements 7, respectively, haveat least one first element having an open distal end at least 1.5 times,or at least 2 times, or at least 3 times larger than the largest distalopen end of a first element located in a land between the two adjacentsecond elements. In one embodiment, the web of the present inventioncomprises at least three adjacent second elements, respectively, have atleast one first element having an open distal end at least 1.5 timeslarger than the largest distal open end of a first element in a landsurrounded the adjacent three second elements. In another embodiment,the web of the present invention comprises at least four adjacent secondelements, respectively, have at least one first element having an opendistal end at least 1.5 times larger than the largest distal open end ofa first element in a land surrounded the adjacent four second elements.

Protrusions

Referring to FIGS. 2A and 2B, in some embodiments, the second elementsare protrusions 7P. The second element 7, a protrusion 7P in this case,has a base 71 in the same plane of the first side 3 of web 1. Referringto FIGS. 13A and 14A-14D, formation of protrusions 7P as second elements7 may have a stretched and enlarged open end of the first elements 4 onthe second element 7 which enables faster fluid acquisition as it maymake more fibers from the nonwoven contact in direct with the fluid.

Protrusion 7P in the web 1 may also be better in stain masking. Fibersoriginated from the nonwoven layer 20 where fluid collected by thelaminate web 1 may be held are not exposed above protrusion 7P which canmake the web 1 appear less red.

In some embodiments, as described below, another characteristic ofprotrusion 7P may be their generally open structure characterized byvoid area defined interiorly of protrusion 7P, as shown in FIG. 2B. By“void area” is not meant an area completely free of any fibers; the termis meant as a general description of the general appearance ofprotrusion 7P. Therefore, it may be that in some protrusion 7P at leastone fibers elongated from the nonwoven layer 20 may be present in thevoid area. From the description of web 1 comprising a nonwoven layer 20,in general, elongated portions 6 comprises fibers 18 that extend fromthe nonwoven layer 20. Elongated portions 6 are not extended above theprotrusion 7P.

Protrusion 7P does not have break or rupture, e.g., by tearing due toextensional failure of the polymer film, so that majority of protrusion7P have no material break between two adjacent first elements,especially in a protrusion base 71. By stating that majority ofprotrusions have no material break between two adjacent first elements,it intends to mean that at least more than 60% of protrusions per 1 cm²laminate web have no material break between two adjacent first elements.

Recesses

Referring to FIGS. 4A and 4B, in other embodiments, the second elements7 are recesses 7R formed inwardly from the first side of the web 1toward the second side of the web 1. A bottom area 10 of the recess 7Rmay be below the second side 5 of the web 1. The bottom area 10 maycomprises a plateau area. In some embodiments, the bottom area 10 of therecess 7R is from about 0.05 mm² to about 15 mm², or from about 0.1 mm²to about 3 mm². The bottom area 10 may be downwardly concaved so thatthere is a very small area of plateau which can prevent the fluid to betrapped between first elements in the bottom area 10. In suchembodiments, referring to FIGS. 15A-17D, recesses 7R may extend belowthe second side 5 of the web 1, so that a bottom area 10 of the recess7R is below the second side 5 of the web 1. In some examples, recesses7R may extend at least about 50 um below the second side 5 of the web 1.

Referring to FIGS. 15A and 16, in one embodiment of the presentinvention, formation of recesses 7R makes the land area have sloped andarched edges due to the specifically designed teeth as explained indetail later. The sloped arch formation on the land area between therecesses also helps fluid drain out of valleys between the firstelements 4. Additionally, extension of polymer film in the recesses 7Rcan be accompanied by stretch of the film and a general reduction inthickness of the film. The stretch and reduction in thickness of thefilm may result in improvement of fluid handling as open ends of thefirst elements 4 can be enlarged. The enlarged open ends in the firstelements 4 help more fibers from the nonwoven contact directly with thefluid.

In addition, as shown in FIGS. 16A and 17A-17D, the first elements 4located in macro structures, recesses 7R in this case, which may bedamaged during formation of the macro structures, are not exposed on orabove either side of the web 1, therefore softness of a surface of theweb 1 is not deteriorated.

Apertures

Referring to FIG. 19, in other embodiments, the second elements 7 may beapertures. The apertures may be formed inwardly from the first side 3 ofthe web toward the second side of the web 1.

Land Area

The laminate web according to the present invention comprises a landarea which surrounds the second elements. Referring to FIGS. 15A-15D and17A-17D, the land area 8 comprises at least one first element 4, or atleast two first elements 4.

Third Elements

The laminate web according to the present invention optionally comprisesa plurality of third elements. The third elements are macro features,and may be selected from the group consisting of apertures, embosses,recesses and a combination thereof. The third elements may be planar andtwo dimensional or three dimensional. “Planar” and “two dimensional” ismeant simply that the web is flat relative to the web 1 that hasdistinct, out-of-plane, Z-direction three-dimensionality due to theformation of the third elements. “Planar” and “two-dimensional” are notmeant to imply any particular flatness, smoothness or dimensionality.Each of the third elements may be formed between two adjacent secondelements. Descriptions provided with respect to a size and density ofthe second elements are applicable for the third elements.

In one embodiment where the laminate web of the present invention usedas a topsheet in an absorbent article such as a sanitary napkin, thethird elements can be only in the region corresponding to the centralpart of the article where fluid entry occurs.

Apparatus and Method for Manufacturing Laminate Web

The first elements 4 and optionally second elements 7 in web 1 can beformed using any processes known in the art. Examples of such processesinclude but are not limited to the following: vacuum forming, mechanicaldeformation, ultrasonics, slitting, ring-rolling, and any combinationthereof.

Methods for vacuum formation, mechanical deformation, and ultrasonicsare described above. With respect to ultrasonics, additional methods aredisclosed in U.S. Pat. Nos. 5,269,981 and 5,269,981. Suitable slittingmethods are disclosed in PCT Publication WO 97/31601. In one embodiment,the second elements of the present invention may be formed by amechanical deformation process. The mechanical deformation process canbe carried out on any suitable apparatus that may comprise any suitabletype(s) of forming structure. Suitable types of forming structuresinclude, but are not limited to: a pair of rolls that define a niptherebetween; pairs of plates; belts, etc. Using an apparatus with rollscan be beneficial in the case of continuous processes, particularlythose in which the speed of the process is of interest. Although theapparatuses will be described herein for convenience primarily in termsof rolls, it should be understood that the description will beapplicable to forming structures comprising a forming member that haveany other suitable configurations.

The rolls for a mechanical deformation process forming first elementsand/or second elements, and optionally the third elements describedherein are typically generally cylindrical. The term “generallycylindrical”, as used herein, encompasses rolls that are not onlyperfectly cylindrical, but also cylindrical rolls that may have elementson their surface. The term “generally cylindrical” also includes rollsthat may have a step-down in diameter, such as on the surface of theroll near the ends of the roll. The rolls are also typically rigid (thatis, substantially non-deformable). The term “substantiallynon-deformable”, as used herein, refers to rolls having surfaces (andany elements thereon) that typically do not deform or compress under theconditions used in carrying out the processes described herein. Therolls can be made from any suitable materials including, but not limitedto steel, aluminum or rigid plastic. The steel may be made of corrosionresistant and wear resistant steel, such as stainless steel. At leastone of the rolls may or be heated. If heated, consideration of thermalexpansion effects must be accommodated according to well known practicesto one skilled in the art of thermo-mechanical processes.

The rolls for a mechanical deformation process forming second elements7, and optionally the third elements described herein have surfaceswhich may be provided with forming elements comprising: male elementssuch as discrete projections such as teeth; female elements such asrecesses such as discrete voids in the surface of the rolls; or anysuitable combination thereof. The female elements may have a bottomsurface (which may be referred to as depressions, or cavities), or theymay be in the form of apertures (through holes in the surface of therolls). In some embodiments, the forming elements on the members such asthe rolls of the forming unit may comprise the same general type (thatis, the opposing components may both have forming elements thereon, orcombinations of forming and mating elements). The forming elements mayhave any suitable configuration. One type of male elements useful in thepresent invention are teeth having a base in a generally polygonal shapesuch as octagonal, hexagonal and quadrilateral shape, and having across-sectional length and a cross-sectional width. The teeth have anysuitable aspect ratio of its cross-sectional length to itscross-sectional width to form macroscopic structures, in a web. In oneembodiment, the teeth have a generally hexagonal shape base. In anotherembodiment, the teeth have a generally quadrilateral shape base.

The male elements can have tips that are flat, rounded or sharp. Incertain embodiments, the shapes of the female elements may differ fromthe shapes of any mating male elements. In certain embodiments, thefemale elements can be configured to mate with one or more maleelements.

A laminate of one embodiment of the present invention may be produced bylaminating a nonwoven web (layer) and a polymer film to obtain aprecursor laminate web, and forming the first elements. Alternatively, alaminate web of the present invention may be produced by laminating anonwoven web (layer) and a polymer film having a plurality of firstelements. The nonwoven web (layer) and the polymer film may be providedeither directly from their respective web making processes or indirectlyfrom supply rolls and moved in the machine direction to the laminatingprocess. Referring to FIG. 5, an exemplary process for producing oneembodiment laminate web 1 comprises a step of laminating a nonwovenlayer 20 and a polymer film layer 21 and a step of forming a pluralityof first elements in first element forming unit 200.

A laminate web of another embodiment of the present invention havingfirst elements and second elements can be produced by laminating anonwoven web (layer) and a polymer film having a plurality of firstelements to obtain a precursor laminate web, and mechanically deformingthe precursor laminate web. The nonwoven web (layer) and the polymerfilm are provided either directly from their respective web makingprocesses or indirectly from supply rolls and moved in the machinedirection to the first elements and second elements forming process. Thelaminate web can be produced by a continuous process comprising a stepof forming a plurality of first elements in a precursor film layer and astep of forming a plurality of second elements via a second elementforming unit. The web also can be produced mechanically deforming apolymer film having a plurality of first elements. Referring to FIGS. 6Aand 6B, exemplary processes for producing web 1 comprise a step offorming a plurality of first elements in first element forming unit 200and a step of forming a plurality of second elements in second elementforming unit 400. The laminate web can also be produced by laminating anonwoven 20 and a polymer film 21 having a plurality of first elementsto obtain a precursor laminate web, and mechanically deforming theprecursor laminate web.

In embodiments illustrated in FIGS. 6A and 6B, second precursor web 21is produced and supplied directly from a film making apparatus such as apolymer film extruder 100 which extrudes a molten film which is to be apolymer film layer 21. FIG. 6A is a schematic representation of aprocess for forming a laminate web of the present invention having aplurality of second elements extended outwardly from a film layer sideof the laminate web such as protrusions. FIG. 6B is a schematicrepresentation of a process for forming a laminate web of the presentinvention having a plurality of second elements extended inwardly from afilm layer side toward a nonwoven layer side of the laminate web such asrecesses and embosses. The extruded polymer film 21 is continuouslymoved to first element forming unit 200. Nonwoven 20 is unwound from thesupply roll 152 and is applied on the second precursor web in the firstelement forming unit 200 so that the first surface 12 of the nonwoven 20is faced with the second surface 15 of the polymer film 21. When thefirst and second precursor webs are laminated on a roll 300, using anidler, nonwoven layer 20 is pressed slightly against the polymer film 21while the polymer film 21 is still molten so that fibers of the nonwoven20 can slightly penetrate into the polymer film 21 and the nonwoven andpolymer film are bonded to each other and form precursor laminate web30. The first element forming unit 200 comprises, for example on itssurface, a vacuum forming slots to form the first elements. Theprecursor laminate web 30 comes into contact with the forming slotsthrough which a strong vacuum is created. The first elements are formedsubstantially only on the film layer 21 as the nonwoven layer 20 isporous and does not interfere with the formation of the first elementson nonwoven 21. The precursor laminate web 30 having the first elementsis moved in the machine direction by means known in the art, includingover or around any of various idler rolls, tension-control rolls, andthe like (all of which are not shown) to second element forming unit400. As an example, the second element forming unit comprises a pair ofcounter-rotating, intermeshing rolls 402 and 404 wherein the first roll402 comprises a plurality of first male elements such as teeth, and thesecond roll 404 comprises a plurality of first female elements.Subsequent to the second element formation, the web 1 can be taken up ona supply roll 160 for storage and optionally for further processing as acomponent in other products. Alternatively, the web 1 can be conveyeddirectly to further post processing, including a converting operationfor incorporation into a finished product, such as a disposableabsorbent product.

In another exemplary process, second precursor web 21 is produced inline, and deformed to have a plurality of first element before beinglaminated with first precursor web 20. The second precursor web 21deformed to have first elements may be laminated with first precursorweb 20 using adhesive or thermal bonding process.

In another exemplary process, polymer film 21 may be a formed filmhaving a plurality of first elements pre-formed. The polymer film 21 issupplied from a separate supply roll and the nonwoven 20 is suppliedonto the second surface 15 of the polymer film 21 to form precursorlaminate web 30. Since the polymer film 21 already has the firstelements, the precursor laminate web 30 is directly supplied to a secondelement formation unit without undergoing the first element formationstep.

FIG. 7 shows in more detail the portion of an exemplary second elementforming unit 450 for a second element forming step to form secondelements 7 in precursor laminate web 30. Second element forming unit 450comprises a pair of intermeshing rolls 452 and 454 rotating in oppositedirections. Second element forming unit 450 can be designed such thatprecursor laminate web 30 remains on roll 452 through a certain angle ofrotation. The second element forming step may be carried out in aprocess speed not causing ruptures or tearing in the second elements.The process speed may be determined considering stretchability of thefilm at the process temperature. While FIGS. 6A, 6B and 7 show precursorlaminate web 30 going straight into and web 1 coming straight out of thenip 416, 456 formed by a pair of rolls of second element forming unit400, 450, precursor laminate web 30 or web 1 can be partially wrapped oneither of first roll 402, 452 or second roll 402, 454 through apredetermined angle of rotation prior to (for precursor laminate web 30)or after (for web 1) the nip. For example, after exiting nip 456, web 1can be directed to be wrapped on roll 452 through a predetermined angleof rotation such that the second elements remain resting over, and“fitted” onto, teeth 410 of roll 452. The second elements having firstelements with enlarged open ends may be stabilized by heat-setting themfilm layer of web 1 during the second element forming step. Web 1, whenit comes out of the nip 416, 456, specifically, the film layer isheat-set to the shape of the second elements so that the film layer doesnot recover back to its original shape such as a flat sheet or close tothe original shape. The heat-set may be conducted by resting over theweb 1 on teeth 410 of heated roll 452 at or near the softening point offilm of the film layer. The heat-set temperature is preferably in therange of ±5° C. of a softening point of the film.

The first roll 452 comprises a plurality of first male elements. In oneembodiment, the plurality of first male elements are formed as rows ofcircumferentially-spaced teeth 410 that extend in spaced relationshipabout at least a portion of roll 452. Teeth 410 can be arranged in astaggered pattern. Teeth 410 extend radially outwardly from the surfaceof the roll 452 to engage grooves 408 of roll 454. The engagement of theteeth 410 and the grooves 408 is shown in greater detail in the crosssectional representation of FIG. 7, discussed below. Both or either ofrolls 452 and 454 can be heated by means known in the art such as byincorporating hot oil filled rolls or electrically-heated rolls.Alternatively, both or either of the rolls may be heated by surfaceconvection or by surface radiation.

Teeth 410 can be joined to roll 452. The term “joined to” encompassesconfigurations in which an element is secured to another element atselected locations, as well as configurations in which an element iscompletely secured to another element across the entire surface of oneof the elements. The term “joined to” includes any known manner in whichelements can be secured including, but not limited to mechanicalentanglement. Teeth can be attached to, such as by welding, compressionfit, or otherwise joined. However, “joined to” also includes integralattachment, as is the case for teeth machined by removing excessmaterial from roll 452. The location at which teeth 410 are joined toroll 452 is a base of a tooth. At any cross-sectional location parallelto the base of each tooth can have a round or a non-roundcross-sectional area. In an alternate embodiment, the teeth may comprisepins that are rectangular or other shapes depending on the correspondingsecond element shape desired.

The second roll 454 can comprise a plurality of first female elements.In one embodiment, the plurality of first female elements are discretegrooves or voids 408 into which one or more of teeth 410 of roll 452mesh. The groove 408 may have the same shape as a base of the teeth 410and slightly larger dimensions on all edges and side than the base ofthe teeth 410. The depth of the grooves 408 may be deeper than a heightof the teeth 410. The grooves 408 may or may not be tapered. In thecase, the spacing of second elements is limited by the spacing of thegrooves 408 on roll 454. A center-to-center distance of two adjacentteeth is a measure between centers of two adjacent teeth. A point wherea major axis and a minor axis of a tooth cross each other is determinedas the center of the tooth.

FIG. 7 shows in cross section a portion of the first roll 452 havingfirst male elements such as teeth 10 and the second roll 454intermeshing each other including representative teeth 410. As shown,teeth 410 have tooth height TH, depth of engagement E, and gap clearanceC. A tooth height TH may range from about 0.5 mm to about 10 mm. Depthof engagement E is a measure of the level of engaging rolls 452 and 454and is measured from a top surface of the roll 454 to top 412 of tooth410 of the roll 452. Gap clearance C is a distance between a top surfaceof the roll 454 and a bottom surface of the roll 452 when rolls 452 and454 are in maximum engagement. Gap clearance is preferably wide enoughto prevent the first elements, especially when the first elements arediscrete extended elements, formed in a precursor web from heat-induceddamages from second element forming step, and thus the first elementsremain substantially intact during second element formation process andsoftness as well as fluid handling of the web is not hindered.Heat-induced damages include permanent deformation of at least part thefirst elements which may cause decrease in diameters of distal open endsof the first elements, hardening part of the first elements as a resultof exposure to the heat. Gap clearance preventing from heat-induceddamages can be determined in consideration of precursor web property,precursor web thickness, height of microtextures, second elementformation process operation conditions such as roll temperature andproduction speed.

It is also contemplated that the size, shape, orientation and spacing ofthe teeth 410 can be varied about the circumference and width of roll452 to provide for varied laminate web 1 properties and characteristics.

Additionally, substances such as lotions, ink, surfactants, and the likecan be sprayed, coated, slot coated, extruded, or otherwise applied toLaminate web 1 before or after entering nip 456. Any processes known inthe art for such application of treatments can be utilized.

Perspective views of exemplary configuration for tooth 410 are shown inFIGS. 8 and 9. As shown in FIG. 8, each tooth 410 has a base 411, atooth top 412, edges 413 and sides 414. Edges 413 and sides 414 may beslightly rounded. Teeth 410 can have a base in a generally polygonalshape. For example, at their base 411, the cross section of teeth 410can have a tooth cross-sectional length TL and a tooth cross-sectionalwidth TW exhibiting a tooth aspect ratio AR of TL/TW of not greater 3.3,or not greater than 2.5, or not greater than 2, or not greater than 1.9.In one embodiment, each of the teeth has a quadrilateral shape base. Theteeth 410 are tapered from the base to the top. In one embodiment, adegree of taper may not be constant along the height of the teeth shownin FIG. 8. In another embodiment, a degree of taper may be constantalong the height of the teeth. The tooth 410 may comprise a proximalpart 420 joined to a member of a second element forming unit, and adistal part 430 directly adjacent to the proximal part and tapering to atooth top 412. The tooth 410 may comprise a proximal part, a distalpart, and a middle part between the proximal part 420 and the distalpart 430. The proximal part and the distal part may have differentdegree of taper from each other. In one embodiment, the distal part 430has a higher degree of taper than the proximal part 420. In anotherembodiment, at least one of the proximal part 420 and the distal part430 has a constant degree of taper. The proximal part is generally afrustum shape tapering from a polygonal-shape base to a point. As shownin FIG. 8, a proximal part 420 can have four sides 414, each side beinggenerally (isosceles) rectangular. The vertex of two sides makes up anedge. The vertices of edges 413 can be machined to have a rounded radiusof curvature. As shown in FIG. 8, a distal part 430 can have a generallyrectangular shape having at least four sides 414′, each side beingsubstantially triangular and tapering from the bottom of the distal partto a tip of the tooth. The vertex of two sides of the distal part 430makes up an edge. The vertices of edges 413′ can be relatively sharp, orcan be machined to have a rounded radius of curvature. The tooth top 412can be flatten, or otherwise slightly shaped so as to stretch but not topuncture the precursor laminate web 30.

In one embodiment, a flattened tooth top 412 can transition to sides 414and the transition can be at a radius of curvature, providing for asmooth, rounded, flattened tooth top. Without being bound by theory, itis believed that having relatively a smooth, rounded, flattened toothtop permits the teeth 410 to form second elements 7 without resulting inapertures or tearing in second elements 7, especially in base 71.

FIG. 9 is another exemplary tooth for a second element forming unitforming.

An exemplary configuration for teeth 410 and arrangement thereof areshown in FIG. 10. Dimensions and a shape of teeth 410 in FIG. 10 areslightly different from those of tooth 410 in FIG. 8. Teeth 410 in FIG.10 having a cross sectional length TL and a cross sectional width TW arearranged in a staggered pattern to have a tooth-to-tooth spacing P_(L)between two adjacent teeth along the cross-sectional length dimension, atooth-to-tooth spacing P_(W) between two adjacent teeth along thecross-sectional width dimension, and a tooth-to-tooth spacing P_(S)between two adjacent teeth along a line that is not parallel either tothe cross-sectional length dimension or to the cross-sectional widthdimension. The teeth 410 may have different lengths of tooth-to-toothspacing P_(S1) and P_(S2), depending on teeth configuration. In oneembodiment as shown in FIG. 10, each of P_(S1) and P_(S2) is constantbetween two staggered adjacent teeth, i.e., between two adjacent teethalong a line that is not parallel either to the cross-sectional lengthdimension or to the cross-sectional width dimension, and it may beeffective to minimize a flat area in the land area where fluid tends tobe trapped in valleys between first elements. For such purposes,lozenge-shaped teeth are preferred especially when they are arranged ina staggered way as the shapes can provide second elements on the web 1well nested and minimize the land area between second elements.Lozenge-shaped teeth may also strain and relax the web 1 to form slightarches in the land area between two adjacent second elements. Byreferring to FIG. 10, the base 411 has a hexagonal shape by slightlycutting out two opposite edges 413 of the proximal part. Edges 413′ ofthe distal part 430 corresponding to the two opposite edges 413 of theproximal part also can be cut out.

In one embodiment, a tooth-to-tooth spacing P_(S) between two adjacentteeth along a line that is not parallel either to the cross-sectionallength dimension or to the cross-sectional width dimension not greaterthan or equal to about 1.5 mm. In another embodiment, at least one ofthe tooth-to-tooth spacing P_(L) and P_(W) is greater than about 1.5 mm.

Of course, tooth-to-tooth spacings P_(L), P_(w) and/or P_(S), toothcross sectional length TL, and tooth cross sectional width TW can eachbe varied independently.

It can be appreciated by the forgoing description that when web 1 ismade by the apparatus and method of the present invention that theprecursor laminate web 30 is stretched during the second elementformation process on the condition that the strain that the secondprecursor web 21 receives is below the strain to break of the secondprecursor web 21 so that the second precursor web 21 elongates to theextent necessary to form second elements without failure, e.g., failuredue to tensile stresses which causes ruptures or tearings in the secondprecursor web 21. For a given maximum strain (e.g., the strain imposedby teeth 410 on a forming member such as a roll) to form secondelements, second precursor web 21 should not fail under the tensileloading produced by the imposed strain locally (i.e., in the area ofstrain). Relative elongation to break values of webs used in the presentinvention can be measured by means known in the art, such as by standardtensile testing methods using standard tensile testing apparatuses, suchas those manufactured by Instron, MTS, Thwing-Albert, and the like.

FIG. 11A shows a portion of an exemplary second element forming unithaving a roll 452 having teeth and a roll 454 intermeshing with roll452. FIG. 11B shows a portion of one embodiment of a roll 452 having aplurality of teeth 410 useful for making a laminate web 1. FIG. 11Cshows a portion of one embodiment of a roll 454 having a plurality ofgrooves 408 useful for making a laminate web 1. FIG. 12 shows a portionof another second element forming unit 400 having a roll 402 havingteeth 410 and a roll 404 having grooves 408 and intermeshing with roll452.

The number, spacing, and size of second elements 7 can be varied bychanging the number, spacing, and size of teeth 410 and makingcorresponding dimensional changes as necessary to roll 402, 452 and/orroll 404, 454. This variation, together with the variation possible inprecursor webs 20, 21 permits many varied webs 1 to be made for manypurposes.

An alternative laminate web having the first elements, the secondelements and third elements can be produced, for example, according toprocess of FIGS. 6A and 6B. Referring to FIGS. 6A and 6B, to producesuch an alternative laminate web, the second roll 404 comprises aplurality of first female elements into which one or more of first maleelements of the first roll 402 mesh to form the second elements, and aplurality of second male elements (not shown in the figures) to form thethird elements on the precursor laminate web 30. The second maleelements may be located between two first female elements. The secondmale elements may be surrounded by at least three first female elements.The second male elements are discrete, and may be of any suitableconfiguration. Descriptions of configuration of the first male elementsare also applicable for the second male elements.

Application of Laminate Web

Laminate webs according to the present invention can be used indisposable absorbent articles such as bandages, wraps, incontinencedevices, diapers, sanitary napkins, pantiliners, tampons, and hemorrhoidtreatment pads, as well as other consumer products such as floorcleaning sheets, body wipes, and laundry sheets.

For example, the aperture web of the present invention can be used inapplications such as products that contact human or non-human animalskin, such as infant-use disposable diapers, adult-use disposablediapers, sanitary napkins, panty liners, incontinence pads, interlabialpads, breast-milk pads, sweat sheets, animal-use excreta handlingarticles, animal-use diapers, and similar various absorbent articles;face masks, base fabric of cooling/heating pads and similarcosmetic/medical-use patches, wound surface protection sheets, nonwovenbandages, hemorrhoid pads, warming devices that directly contact theskin (e.g. disposable hand warmers), base fabric of various animal-usepatches, and similar skin covering sheets; makeup removal sheets,anti-perspirant sheets, bottom wipes and similar wipes for use on aperson, various wiping sheets for use on animals, and the like. The webof the present invention is preferably used as a topsheet for anabsorbent article. In one embodiment, the first side of the web 1 havinga plurality of discrete extended elements is in contact with the skin.In another embodiment, the second side comprising nonwoven layer of theweb 1 is in contact with the skin.

Absorbent Article

An absorbent article according to the present invention comprises atopsheet and a backsheet joined to the topsheet, wherein the topsheetcomprises the apertured web according to the present invention. It mayfurther comprise an absorbent core between the topsheet and thebacksheet. The absorbent articles may be produced industrially by anysuitable means. The different layers may thus be assembled usingstandard means such as embossing, thermal bonding, or gluing orcombination of both.

Topsheet

With the apertured web according to the present invention, a surface ofthe web having a plurality discrete extended elements is preferably,disposed on a side in contact with the skin.

Backsheet

Any conventional backsheet materials commonly used for absorbentarticles may be used as backsheet. In some embodiments, the backsheetmay be impervious to malodorous gases generated by absorbed bodilydischarges, so that the malodors do not escape. The backsheet may or maynot be breathable.

Absorbent Core

It may be desirable that the article further comprises an absorbent coredisposed between the topsheet and the backsheet. As used herein, theterm “absorbent core” refers to a material or combination of materialssuitable for absorbing, distributing, and storing fluids such as urine,blood, menses, and other body exudates. Any conventional materials forabsorbent core suitable for absorbent articles may be used as absorbentcore.

Test Methods

Artificial Menstrual Fluid (“AMF”) Preparation

AMF is composed of a mixture of defibrinated sheep blood, a phosphatebuffered saline solution and a mucous component, and has a viscositybetween 7.15 to 8.65 cSt at 23° C.

Viscosity on the AMF is performed using a low viscosity rotaryviscometer such as Cannon LV-2020 Rotary Viscometer with UL adapter(Cannon Instrument Co., State College, US) or equivalent. Theappropriate size spindle for the viscosity range is selected, andinstrument is operated and calibrated as per the manufacturer.Measurements are taken at 23° C.±1° C. and at 60 rpm. Results arereported to the nearest 0.01 cSt.

Defibrinated Sheep Blood

Defibrinated sheep blood with a packed cell volume of 38% or greatercollected under sterile conditions (available from Cleveland Scientific,Inc., Bath, Ohio, US) or equivalent is used.

Phosphate Buffered Saline Solution

The phosphate buffered saline solution consists of two individuallyprepared solutions (Solution A and Solution B). To prepare 1 L ofSolution A, add 1.38±0.005 g of sodium phosphate monobasic monohydrateand 8.50±0.005 g of sodium chloride to a 1000 mL volumetric flask andadd distilled water to volume. Mix thoroughly. To prepare 1 L ofSolution B, add 1.42±0.005 g of sodium phosphate dibasic anhydrous and8.50±0.005 g of sodium chloride to a 1000 mL volumetric flask and adddistilled water to volume. Mix thoroughly. Add 450±10 mL of Solution Bto a 1000 mL beaker and stir at low speed on a stir plate. Insert acalibrated pH probe (accurate to 0.1) into the beaker of Solution B andadd enough Solution A, while stirring, to bring the pH to 7.2±0.1.

Mucous Component

The mucous component is a mixture of the phosphate buffered salinesolution, potassium hydroxide aqueous solution, gastric mucin and lacticacid aqueous solution. The amount of gastric mucin added to the mucouscomponent directly affects the final viscosity of the prepared AMF. Asuccessful range of gastric mucin is usually between 38 to 50 grams. Toprepare about 500 mL of the mucous component, add 460±10 mL of thepreviously prepared phosphate buffered saline solution and 7.5±0.5 mL ofthe 10% w/v potassium hydroxide aqueous solution to a 1000 mL heavy dutyglass beaker. Place this beaker onto a stirring hot plate and whilestirring, bring the temperature to 45° C.±5° C. Weigh the pre-determinedamount of gastric mucin (±0.50 g) and slowly sprinkle it, withoutclumping, into the previously prepared liquid that has been brought to45° C. Cover the beaker and continue mixing. Over a period of 15 minutesbring the temperature of this mixture to above 50° C. but not to exceed80° C. Continue heating with gentle stirring for 2.5 hours whilemaintaining this temperature range, then remove the beaker from the hotplate and cool to below 40° C. Next add 1.8±0.2 mL of the 10% v/v lacticacid aqueous solution and mix thoroughly. Autoclave the mucous componentmixture at 121° C. for 15 minutes and allow 5 minutes for cool down.Remove the mixture of mucous component from the autoclave and stir untilthe temperature reaches 23° C.±1° C.

Allow the temperature of the sheep blood and mucous component to come to23° C.±1° C. Using a 500 mL graduated cylinder, measure the volume ofthe entire batch of the mucous component and add it to a 1200 mL beaker.Add an equal volume of sheep blood to the beaker and mix thoroughly.Using the viscosity method previously described, ensure the viscosity ofthe AMF is between 7.15-8.65 cSt. If not the batch is disposed andanother batch is made adjusting the mucous component as appropriate.

The qualified AMF should be refrigerated at 4° C. unless intended forimmediate use. AMF may be stored in an air-tight container at 4° C. forup to 48 hours after preparation. Prior to testing, the AMF must bebrought to 23° C.±1° C. Any unused portion is discarded after testing iscomplete.

Acquisition Time Measurement

Acquisition time is measured for an absorbent article loaded withArtificial Menstrual Fluid (AMF) as described herein, using astrikethrough plate and an electronic circuit interval timer. The timerequired for the absorbent article to acquire a dose of AMF is recorded.All measurements are performed in a laboratory maintained at 23° C.±2°C. and 50%±2% relative humidity.

Referring to FIGS. 21A-21E, the strikethrough plate 9001 is constructedof Plexiglas with an overall dimension of 10.2 cm long by 10.2 cm wideby 3.2 cm tall. A longitudinal channel 9007 running the length of theplate is 13 mm deep and 28 mm wide at the top plane of the plate, withlateral walls that slope downward at 65° to a 15 mm wide base. A centraltest fluid well 9009 is 26 mm long, 24 mm deep and 38 mm wide at the topplane of the plate with lateral walls that slope downward at 65° to a 15mm wide base. At the base of the test fluid well 9009, there is an “H”shaped test fluid reservoir 9003 open to the bottom of the plate for thefluid to be introduced onto the underlying article. The test fluidreservoir 9003 has an overall length (“L”) of 25 mm, width (“W”) of 15mm, and depth (“D”) of 8 mm. The longitudinal legs of the reservoir are4 mm wide and have rounded ends with a radius 9010 of 2 mm. The legs are3.5 mm apart. The central strut has a radius 9011 of 3 mm and houses theopposing electrodes 9004 6 mm apart. The lateral sides of the reservoirbow outward at a radius 9012 of 14 mm bounded by the overall width, W,of 15 mm. Two wells 9002 (80.5 mm long×24.5 mm wide×25 mm deep) locatedoutboard of the lateral channel, are filled with lead shot to adjust theoverall mass of the plate to provide a constraining pressure of 0.25 psi(17.6 gf/cm²) to the test area. Electrodes 9004 are embedded in theplate 9001, connecting the exterior banana jacks 9006 to the inside wallof the fluid reservoir 9003. A circuit interval timer is plugged intothe jacks 9006 to the inside wall 9005 of the fluid reservoir 9003. Acircuit interval timer (not shown in the drawings) is plugged into thejacks 9006, and monitors the impedance between the two electrodes 9004,and measures the time from introduction of the AMF into reservoir 9003until the AMF drains from the reservoir. The timer has a resolution of0.01 sec.

Test products are removed from all packaging using care not to pressdown or pull on the products while handling. No attempt is made tosmooth out wrinkles. The test samples are conditioned at 23° C.±2° C.and 50%±2% relative humidity for at least 2 hours prior to testing.

The required mass of the strikethrough plate must be calculated for thespecific dimensions of the test article such that a confining pressureof 1.72 kPa is applied. Determine the longitudinal and lateral midpointof the article's absorbent core. Measure and record the lateral width ofthe core to the nearest 0.1 cm. The required mass of the strikethroughplate is calculated as the core width multiplied by strikethrough platelength (10.2 cm) multiplied by 17.6 gf/cm² and recorded to the nearest0.1 g. Add lead shot to the plate to achieve the calculated mass.

Connect the electronic circuit interval timer to the strikethrough plate9001 and zero the timer. Place the test product onto a flat, horizontalsurface with the body side facing up. Gently place the strikethroughplate 9001 onto the center of the test product ensuring that the “H”shaped reservoir 9003 is centered over the test area.

Using a mechanical pipette, accurately pipette 4.00 mL±0.05 mL of AMFinto the test fluid reservoir 9003. The fluid is dispensed, withoutsplashing, along the molded lip of the bottom of the reservoir 9003within a period of 3 seconds or less. After the fluid has been acquired,record the acquisition time to the nearest 0.01 second. Thoroughly cleanthe electrodes 9004 before each test.

In like fashion, a total of three (3) replicate samples are tested foreach test product to be evaluated. Report the Acquisition Time (sec) asthe mean of the replicates to the nearest 0.01 sec.

Stain Perception Measurement

Stain perception is measured by the size and color intensity of a fluidstain visible on an absorbent article. Artificial menstrual fluid (AMF)is dosed onto the surface of an article, and is photographed undercontrolled conditions. The photographic image is then calibrated andanalyzed using image analysis software to obtain measurements of thesize and color intensity of the resulting visible stain. Allmeasurements are performed at constant temperature (23° C.±2° C. andrelative humidity (50%±2%).

The absorbent article, a calibrated color standard containing 24standard color chips such as ColorChecker Passport (X-Rite; GrandRapids, Mich., US) or equivalent, and a calibrated ruler are laidhorizontally flat on a matte black background inside a light box thatprovides stable uniform lighting evenly across the entire base of thelight box. A suitable light box is the Sanoto MK50 (Sanoto, Guangdong,China), or equivalent, which provide an illumination of 5500 LUX at acolor temperature of 5500K. A Digital Single-Lens Reflex (DSLR) camerawith manual setting controls (e.g. a Nikon D40X available from NikonInc., Tokyo, Japan, or equivalent) is mounted directly above an openingin the top of the light box so that the entire article, color standardand ruler are visible within the camera's field of view.

Using a standard 18% gray card (e.g., Munsell 18% Reflectance (Gray)Neutral Patch/Kodak Gray Card R-27, available from X-Rite; Grand Rapids,Mich., US or equivalent), the camera's white balance is custom set forthe lighting conditions inside the light box. The camera's manualsettings are set so that the image is properly exposed such that thereis no signal clipping in any of the color channels. Suitable settingsmight be an aperture setting of f/11, an ISO setting of 400, and ashutter speed setting of 1/400 sec. At a focal length of 35 mm thecamera is mounted approximately 14 inches above the article. The imageis properly focused, captured, and saved as a JPEG file. The resultingimage must contain the entire article, color target, and calibratedruler at a minimum resolution of 15 pixels/mm.

Absorbent article samples are conditioned at 23° C.±2° C. and 50%±2%relative humidity for 2 hours prior to testing. Place a sample articleflat, with the top sheet of the sample facing upward, on the mattesurface within the light box along with the ruler and color standard.Using a mechanical pipette held approximately 5 mm above the samplesurface, a loading of 1.0 mL±0.05 mL of AMF is slowly and steadilyloaded onto the center of the article over a 5 second time period. Twoadditional 1.0 mL loadings are applied in the same location and in likefashion at 2 minute intervals for a total of 3.0 mL of AMF. Images arecaptured at 2 minutes and again at 5 minutes after the third loading.

To analyze the image, it is first transferred to a computer running animage analysis software (a suitable software is MATLAB, available fromThe Mathworks, Inc, Natick, Mass., or equivalent).

The image is color calibrated using the true tristimulus XYZ color spacevalues provided by the manufacturer for each of the 24 color chips inthe color target. If target values are given in L*a*b* they areconverted to XYZ according to the standard equations. The values areidentified as X_(true1 . . . 24), Y_(true1 . . . 24), andZ_(true1 . . . 24). Using the image analysis software the mean red,green, and blue (RGB) values of each of the 24 color chips in the imageare measured using a square region of interest that covers approximately75% of the interior area of each individual color chips. These valuesare identified as R_(1 . . . 24), G_(1 . . . 24), and B_(1 . . . 24). Asystem of 24 equations, using the X_(true) and associated RGB values foreach color tile, is set up according to the following example:

X_(true 1) = α₁ + α₂R₁ + α₃G₁ + α₄B₁ + α₅R₁² + α₆R₁G₁ + α₇G₁² + α_(B)R₁B₁ + α₉G₁B₁ + α₁₀B₁²⋮X_(true 24) = α₁ + α₂R₂₄ + α₃G₂₄ + α₄B₂₄ + α₅R₂₄² + α₆R₂₄G₂₄ + α₇G₂₄² + α₈R₂₄B₂₄ + α₉G₂₄B₂₄ + α₁₀B₂₄²

A second system of 24 equations, using the Y_(true) and associated RGBvalues for each color tile, is set up according to the followingexample:

Y_(true 1) = β₁ + β₂R₁ + β₃G₁ + β₄B₁ + β₅R₁² + β₆R₁G₁ + β₇G₁² + β_(B)R₁B₁ + β₉G₁B₁ + β₁₀B₁²⋮Y_(true 24) = β₁ + β₂R₂₄ + β₃G₂₄ + β₄B₂₄ + β₅R₂₄² + β₆R₂₄G₂₄ + β₇G₂₄² + β₈R₂₄B₂₄ + β₉G₂₄B₂₄ + β₁₀B₂₄²

A third system of 24 equations, using the Z_(true) and associated RGBvalues for each color tile, is set up according to the followingexample:

Z_(true 1) = γ₁ + γ₂R₁ + γ₃G₁ + γ₄B₁ + γ₅R₁² + γ₆R₁G₁ + γ₇G₁² + γ_(B)R₁B₁ + γ₉G₁B₁ + γ₁₀B₁²⋮Z_(true 24) = γ₁ + γ₂R₂₄ + γ₃G₂₄ + γ₄B₂₄ + γ₅R₂₄² + γ₆R₂₄G₂₄ + γ₇G₂₄² + γ₈R₂₄B₂₄ + γ₉G₂₄B₂₄ + γ₁₀B₂₄²

Using the 24 X_(true) equations, each of the ten α coefficients aresolved for using the standard equation y=Ax, where y are the X_(true),Y_(true), and Z_(true) vectors, A is the list of the measured RGBintensities, and x is a vector of the unknown alpha (α), beta (β), orgamma (γ) coefficients to be estimated.

For example, to solve for the α's in the transform that converts the RGBcolors into colorimetric X tristimulus value, the arrays are as follows:

$\overset{\Cap}{x} = \begin{bmatrix}\alpha_{1} \\\vdots \\\alpha_{10}\end{bmatrix}$ $A = \begin{bmatrix}1 & R_{1} & G_{1} & B_{1} & R_{1}^{2} & \cdots & B_{1}^{2} \\\vdots & \vdots & \vdots & \vdots & \vdots & \ddots & \vdots \\1 & R_{24} & G_{24} & B_{24} & R_{24}^{2} & \cdots & B_{24}^{2}\end{bmatrix}$ $y = \begin{bmatrix}X_{{true}\; 1} \\\vdots \\X_{{true}\; 24}\end{bmatrix}$

The solution of the normal equations for x provides the least squaressolution for the ten α coefficients according to the following equation:{circumflex over (x)}=(A ^(T) A)⁻¹ A ^(T) y

This procedure is repeated using the 24 Y_(true) equations to solve forthe ten β coefficients, and the 24 Z_(true) equations to solve for theten γ coefficients.

These coefficients are then plugged back into the original equations toprovide three transform equations one each for X, Y, and Z, by which theRGB values for each individual pixel in the image are transformed intocalibrated XYZ values. For example, the RGB transform equation for Xusing the 10 α coefficients is as follows:X=α ₁+α₂ R+α ₃ G+α ₄ B+α ₅ R ²+α₆ RG+α ₇ G ²+α₈ RB+α ₉ GB+α ₁₀ B ²

The XYZ values are then converted into CIE 1976 L*a*b* values as definedin CIE 15:2004 section 8.2.1.1 using D65 reference white.

The image resolution is calibrated using the calibrated distance scalein the image to determine the number of pixels per millimeter.

Separate images are generated for each of the individual L*, a*, and b*channels. The Chroma image is calculated using the following formula:Chroma=√{square root over ((a*)²+(b*)²)}

Where a* and b* are the individual colorimetric images. The chroma imageis analyzed by manually drawing the region of interest (ROI) boundaryaround the visibly discernable perimeter of the stain. The area of theROI is calculated and recorded to the nearest 0.1 mm² and the meanChroma value within the ROI is calculated and recorded to the nearest0.1 units.

The same ROI is analyzed for the a* image alone, and the mean a* valuewithin the ROI is calculated and recorded to the nearest 0.1 units.

A minimum bounding rectangle is drawn around the ROI. This is thesmallest rectangle that can be drawn within which all of the points ofthe ROI lie. The edges of the rectangle are parallel and perpendicularto the longitudinal and lateral axis of the absorbent article, such thatthe ROI height (H) is defined as the height of the bounding rectanglealong the longitudinal axis of the article, and the ROI width (W) isdefined as the width of the bounding rectangle along the lateral axis ofthe article. Both H and W are recorded to the nearest 0.1 mm.

This entire procedure is repeated on three substantially similarreplicate articles. The reported value is the average of the threeindividual recorded measurements for stain area to the nearest 0.1 mm²,mean Chroma and a* to the nearest 0.1 units, and H and W to the nearest0.1 mm. All measurements are made and recorded separately for both thephotographic images collected at the 2 minute and 5 minute time points.

Fiber-Fiber Distance Measurement

Z-direction distances between individual fibers in a nonwoven layer in alaminate sample having a film layer and a nonwoven layer is measuredusing micro-CT fiber-to-fiber distance measurement based on analysis ofa 3D x-ray image of a sample obtained on a micro-CT instrument having acone beam microtomograph with a shielded cabinet such as Scanco μCT 50(Scanco Medical AG, Switzerland) and equivalents. A maintenance freex-ray tube is used as the source with an adjustable diameter focal spot.The x-ray beam passes through the sample, where some of the x-rays areattenuated by the sample. The extent of attenuation correlates to themass of material the x-rays have to pass through. The transmitted x-rayscontinue on to the digital detector array and generate a 2D projectionimage of the sample. Multiple individual projection images of thesample, generated as it is rotated, are collected and then reconstructedinto a single 3D image. The instrument is interfaced with a computerrunning software to control the image acquisition and reconstruction ofthe raw data into a 3D image. The 3D image is then analyzed using imageanalysis software such as MATLAB (The Mathworks, Inc., MA, USA) andAvizo Lite (Visualization Sciences Group/FEI Company, MA, USA) andequivalents to identify and segment out the film layer from the nonwovenlayer, and measure Z-direction distances between individual fibers inthe nonwoven portion of the laminate sample.

Sample Preparation:

To obtain a sample for measurement, lay a film-nonwoven laminate outflat and die cut a circular piece with a diameter of 7 mm. If thelaminate is a component of an absorbent article, tape the absorbentarticle to a rigid flat surface in a planar configuration, and carefullyseparate the laminate from the other components of the absorbentarticle. A scalpel and/or cryogenic spray such as Cyto-Freeze (ControlCompany, TX, USA) can be used to remove the laminate from the othercomponents of the absorbent article, if necessary, to avoid extension ofthe laminate. Once the laminate has been removed from the article,proceed with die cutting the sample as described above.

A sample may be cut from any location containing the laminate to beanalyzed. When selecting a location for sampling, care should be takento avoid embossed regions, if any, in the absorbent article where thelaminate may have been crushed and/or compressed during the articlemaking process, as well as any folds, wrinkles or tears.

Image Acquisition:

The micro-CT instrument is set up and calibrated according to themanufacturer's specifications. The sample is placed into an appropriateholder, between two rings of a low density material, such as foam, whichhave an inner diameter of at least 4 mm. This allows the central regionof the sample to lay horizontal and be scanned without having any othermaterials directly adjacent to its upper and lower surfaces. Analysis isperformed within this central region. A single 3D dataset of contiguous3 μm isotropic voxels is collected. The 3D dataset is centered on thecentral analysis region, having dimensions of 7 mm on each side in theXY-plane and a sufficient number of slices to fully include theZ-direction of the sample. Images are acquired with the source at 45 kVpand 88 μA with no additional low energy filter. Current and voltagesettings may be optimized to produce the maximum contrast in theprojection data with sufficient x-ray penetration through the sample,but once optimized held constant for all substantially similar samples.A total of 3200 projection images are obtained with an integration timeof 1000 ms and 3 averages. The projection images are reconstructed usingacquisition and reconstruction software accompanies the instrument intoa 3D dataset having an isotropic spatial resolution of 3 μm, and savedin 16-bit RAW format to preserve the full detector output signal foranalysis.

Image Processing:

The 3D dataset is loaded into the image analysis software, and trimmedto a rectangular prism 3D image of the analysis region by removing thesurrounding holder and the low density mounting material from the 3Ddataset. Trimming is performed such that the maximum amount of thesample in the analysis region is retained in the 3D image, and the emptyspace above and below the sample is minimized. The trimmed 3D image isscaled from 16-bit to 8-bit for the purpose of convenience in dataanalysis, and thresholded using Otsu's method which calculates thethreshold level that minimizes the weighted intra-class variance, toseparate and remove the background signal due to air, but maintain thesignal from the film and fibers within the sample image. Film and/orfiber containing voxels are referred to as “material” voxels.

A connected components algorithm is executed on the trimmed 3D image,which identifies and groups together any material voxels that are26-connected (touching one of their faces, edges, or corners) to anyneighboring material voxels. Any material voxel clusters containingfewer than 1000 connected voxels are identified as noise and removedfrom the 3D image.

The 3D image is oriented so that the film upper surface is as close toparallel with the XY-plane as possible.

The film layer is identified and distinguished from nonwoven fibersusing a Z-direction vector, such that given an XY-plane position, atypical Z-direction vector traveling from the top of the 3D image to thebottom will first pass through the film, and then pass throughunderlying nonwoven fibers. However, in the regions where aperturesformed in the film layer, a fiber may be the first material encountered,and must be distinguished from the film layer. As an individualZ-direction vector travels from the top of the 3D image downward, theremay be a series of contiguous material voxels in the vector as it passesthrough the first material encountered. The last material voxel in thisseries of contiguous material voxels is identified as a potential lowerfilm surface or “bottom of film” voxel. This process is repeated as aZ-direction vector is passed through every XY-plane position in the 3Dimage, and all of the potential bottom of film voxels are identified. Aconnected components algorithm is once again executed on only theidentified potential bottom of film voxels in the 3D image, which groupstogether potential bottom film voxels that are 26-connected (touchingone of their faces, edges, or corners) to neighboring potential bottomof film voxels. The lower surface of the film is identified as thesingle largest continuous cluster of potential bottom of film voxels.

The fiber-to-fiber distance is measured along the Z-direction vectors,below the identified lower surface of the film layer from where onefiber ends to the beginning of the next underlying fiber. If no filmvoxel was identified in the Z-direction vector, due to a hole oraperture in the film layer, any distance measurements from that vectorare ignored. Any Z-direction vectors which do not encounter any fibersare also ignored. The median fiber-to-fiber distance of all the distancemeasurements in the 3D image is calculated and recorded to the nearest0.1 μm. A total of three substantially similar replicate film-nonwovenlaminate samples are analyzed in like manner, and the average of thethree recorded median fiber-to-fiber distances is reported to thenearest 0.1 μm.

EXAMPLES Example 1: Sample Preparation I

Laminate 1 having a plurality of first elements 4 and a plurality ofprotrusion 7P was produced according to process of FIG. 6A againstsecond element forming unit of FIGS. 7 and 11A. 15 gsm air-throughcarded nonwoven produced from 6 denier PE/PET bicomponent polymers, and12 gsm polymer film produced from polyethylene resin using a filmextruder were used to produce laminate 1. The nonwoven was supplied ontothe second surface of the polymer film to form a precursor laminatewhile the film was still softened enough to bond to the nonwoven. Theprecursor laminate was fed into the vacuum forming section to form firstelements on the polymer film. The precursor laminate having firstelements was fed to a second element forming unit to form protrusions toobtain laminate 1. The teeth are arranged in a staggered pattern, andoriented to having a major axis in a MD and a minor axis in a CD. Themale roll was heated about 80° C., the softening point of thepolyethylene film of the film layer.

FIGS. 13A and 14A are scanning electron microscope (“SEM”) (Quanta 450,FEI) images of a film side of laminate 1. FIG. 13B is a SEM (Quanta 450,FEI) image of a nonwoven side of laminate 1. 7P1, 7P2 and 7P3 in FIG.14A indicate individual protrusions 7P. FIGS. 14B-14D are SEM (Quanta450, FEI) images of more highly magnified portions of laminate 1 of FIG.14A showing areas in a film side around protrusions 7P1, 7P2 and 7P3,respectively. It was observed that second elements 7, protrusions 7P inthis case, have an arched wall, and a first element 4 having an enlargedopen end. It was also observed that there are two adjacent protrusions7P each of which has one or more than one first element 4 having an opendistal end at least 1.5 times larger than the largest distal open end ofa first element 4 in a land 8 between the two adjacent protrusions 7P.It was also observed that there is no tearings or ruptures in theprotrusion 7P.

Laminate 2 having a plurality of first elements 4 and a plurality ofprotrusions was produced according to the same process to producelaminate 1. 15 gsm air-through carded nonwoven produced from 3 denierPE/PET bicomponent polymers, and 12 gsm polymer film produced frompolyethylene resin using a film extruder were used to produce laminate2.

Laminate 3 having a plurality of first elements 4 and a plurality ofprotrusions 7P was produced according to the same method employed toproduce laminate 1. 10 gsm spunbond nonwoven produced from 2.5 denier PPpolymers, and 12 gsm polymer film produced from polyethylene resin usinga film extruder were used to produce laminate 3.

Laminates 4-6 having first elements 4 identical to those of laminate 1and not having protrusions were produced according to the same processfor producing laminate 1 except conducing the second element formationstep. Laminate 4 was produced using a film layer and a nonwoven layerthe same as those for laminate 1. Laminate 5 was produced using a filmlayer and a nonwoven layer the same as those for laminate 2, andlaminate 5 was produced using a film layer and a nonwoven layer the sameas those for laminate 3.

Sanitary napkin samples 1-6 were produced using Always Thin Long Superwith Wing (Procter and Gamble Company, US) by removing topsheets andusing laminates 1-6 produced above as topsheets, respectively. Sanitarynapkins (Always Thin Long Super with Wing) were removed from packages,and unfolded. A freeze spray was applied on the topsheet side of thesanitary napkins, and topsheets were carefully removed from the sanitarynapkins. Then new topsheets formed by laminates 1-6, respectively, wereapplied onto the topsheet-removed sanitary napkins and the new topsheetand the topsheet-removed sanitary napkins were sandwiched with no glueto obtain samples 1-6 having laminates 1-6, respectively. Samples wereallowed to equilibrate to the controlled room temperature for at leasttwo hours prior to testing.

Example 2: Sample Preparation II

Laminate 7 having a plurality of first elements 4 and a plurality ofrecesses 7R was produced according to the same process to producelaminate 1. 15 gsm air-through carded nonwoven produced from 6 denierPE/PET bicomponent polymers, and 12 gsm polymer film produced frompolyethylene resin using a film extruder were used to produce laminate7. The nonwoven was supplied onto the second surface of the polymer filmto form a precursor laminate while the film was still softened enough tobond to the nonwoven. The precursor laminate was fed into the vacuumforming section to form first elements on the polymer film. Theprecursor laminate having first elements was fed to a second elementforming unit to form recesses to obtain a laminate web. The teeth arearranged in a staggered pattern, and oriented to having a major axis ina MD and a minor axis in a CD. The male roller was heated about 80° C.,the softening point of the polyethylene film of the film layer.

Laminate 8 having a plurality of first elements 4, a plurality ofrecesses 7R was produced according to the same process to producelaminate 1. 10 gsm spunbond nonwoven produced from 2.5 denier PPpolymers, and 12 gsm polymer film produced from polyethylene resin usinga film extruder were used to produce laminate 8.

FIGS. 15A and 15B are SEM (Quanta 450, FEI) images of a nonwoven layerside and a film side of highly magnified portions of Laminate 4,respectively. FIG. 16 is a SEM (Quanta 450, FEI) image of a crosssection of laminate 7 in the width direction of the recesses 7R oflaminate 7. It was observed that the recess 7R has a sloped sidewall 6and a bottom area 10 concaved and the bottom area 10 has a very smallarea of plateau, and has multiple first elements having open ends.

FIG. 17A is a SEM (Quanta 450, FEI) image of highly magnified portionsof a nonwoven layer side of laminate 8. FIGS. 17B-17D are SEM (Quanta450, FEI) images of more highly magnified portions of FIG. 17A,including recesses 7R1, 7R2 and 7R3 indicated in FIG. 17A, respectively.

Sanitary napkin samples 7 and 8 were prepared using Always Thin LongSuper with Wing (Procter and Gamble Company, US) according to thepreparation disclosed in Example 1 with topsheets formed by laminate 7and laminate 8 produced above, respectively. Sample 9 was prepared usingAlways Thin Long Super with Wing (Procter and Gamble Company, US) byremoving a topsheets and using a topsheet removed from a commerciallyavailable sanitary pad, Dollar General Health Ultra Thin Long Super withWings (hereinafter “DG Ultra”) (First Quality, US). FIGS. 18A and 18Bare a light microscope (Discovery V20 Stereolight microscope with a MRC5Camera, Zeiss) images of a film side (skin-facing side) of the removedtopsheet and a cross section thereof. It was observed that the Y-shapeembossed areas were compressed and flat, and had substantially noapertures. Samples were allowed to equilibrate to the controlled roomtemperature for at least two hours prior to testing.

Example 3: Acquisition Time

Acquisition times of samples 1-7 and 9 obtained in Examples 1 and 2 weremeasured according to Acquisition Time Measurement described under TESTMETHODS above and results are indicated in Table 1.

TABLE 1 Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Topsheet Laminate 1Laminate 2 Laminate 3 Laminate 4 Laminate 5 (film/6denier (film/3denier(film/2.5denier (film/6denier (film/3denier nonwoven) nonwoven) spunbondnonwoven) nonwoven) nonwoven) Topsheet First First First First First 3Dstructure elements and elements and elements and elements elementsprotrusions protrusions protrusions only only Acquisition 9.63 8.3711.03 25.3 16.1 time (sec) Sample 6 Sample 7 Sample 9 Topsheet Laminate6 Laminate 7 Film/nonwoven construction (film/2.5denier (film/6denierspunbond nonwoven) nonwoven) Topsheet First First apertures and 3Dstructure elements elements and embossing only recesses Acquisition 21.319.3 30.4 time (sec)

Acquisition times of sample 8 and sample 6 were separately measuredaccording to Acquisition Time Measurement described under TEST METHODSabove and results are indicated in Table 2.

TABLE 2 Sample 8 Sample 6 Topsheet construction Laminate 8 Laminate 6(film/2.5denier (film/2.5denier spunbond spunbond nonwoven) nonwoven)Topsheet 3D structure First elements First elements only and recessesAcquisition time (sec) 18.15 28.95

Example 4: Stain Perception

Mean Chromas of samples 1-7 and 9 obtained in Examples 1 and 2 weremeasured at 5 minute time point according to Stain PerceptionMeasurement under TEST METHODS above, and are indicated in Table 3.

TABLE 3 Sam- Sam- Sam- Sam- Sam- Sam- Sam- Sam- ple 1 ple 2 ple 3 ple 4ple 5 ple 6 ple 7 ple 9 Mean Chroma 12.17 13.10 12.83 14.85 44.49 40.279.13 22.80 after 5 min

FIGS. 22-28 are macroscopic images of samples 1-7 and FIG. 31 is amacroscopic image of sample 9 obtained at 5 minute time point obtainedin the Stain Perception Measurement under TEST METHODS above.

Mean chromas of sample 8 obtained in Example 2 and sample 6 obtained inExample 1 were measured at 5 minute time point according to StainPerception Measurement under TEST METHODS above, and are indicated inTable 4.

TABLE 4 Sample 8 Sample 6 Mean Chroma after 5 min 16.89 44.96

FIGS. 29 and 30 are microscopic images of samples 8 and 6, respectivelyobtained at 5 minute time points obtained in the Stain PerceptionMeasurement.

Example 5: Sample Preparation III

Laminate 10 having a plurality of first elements (70 mesh) and aplurality of apertures (28 to 29 apertures/cm²) as second elements wasproduced according to a process schematically depicted in FIG. 6Bagainst second element forming unit similar to one shown in FIG. 12. 15gsm air-through carded nonwoven produced from 6 denier PE/PETbicomponent fibers, and 12 gsm polymer film produced from polyethyleneresin using a film extruder were used to produce laminate 10. The cardednonwoven with a high caliper was produced by optimizing nonwovenproduction conditions such as oven air flow temperature, hot airpressure and web tension when going through the oven and/or calendarrolls. The carded nonwoven was supplied onto the second surface of thepolymer film to form a precursor laminate while the film was still hotenough to bond to the nonwoven.

Laminate 11 having the same discrete extended elements (70 mesh) andapertures (28 to 29 apertures/cm²) as those for laminate 10 was producedaccording to a process schematically depicted in FIG. 6B havingequipment of FIG. 12 using 10 gsm spunbond nonwoven produced from 2.5denier PP fibers, and 12 gsm polymer film produced from polyethyleneresin using a film extruder.

Polymer film 1 having the same discrete extended elements (70 mesh) andapertures (24 to 25 apertures/cm²) was produced using 22.4 gsm polymerfilm produced from polyethylene resin using a film extruder.

FIGS. 19 and 20 are 20× light microscope (Discovery V20 Stereolightmicroscope with a MRC5 Camera, Zeiss) images of film sides of laminate10 and polymer film 1, respectively.

Sanitary napkin samples 10, 11 and 12 were produced according to themethod described in Example 1 using topsheets formed by laminates 10 and11, and polymer film 1, respectively. Samples were allowed toequilibrate to the controlled room temperature for at least two hoursprior to testing.

Example 6: Acquisition Time and Stain Perception

Acquisition times of samples 10 and 11 were measured according toAcquisition Time Measurement under TEST METHODS above, and results areindicated in Table 5. Mean chromas of samples 10 and 11 were measuredaccording to Stain Perception Measurement at 2 minute time point underTEST METHODS above, and results are indicated in Table 5.

TABLE 5 Sample 10 Sample 11 Film layer PE film, 12 gsm PE film, 12 gsmNonwoven layer Carded nonwoven Spunbond nonwoven formed by 6 formed by2.5 denier PE/PET denier PP polymer, bico polymers, 10 gsm 15 gsm Firstelement discrete extended discrete extended elements elements Secondelement Apertures Apertures Acquisition 12.4 16.5 time (sec) Mean Chrom13.4 17.8 after 2 min

FIGS. 32 and 33 are microscopic images of sample 10 and comparativesample 11, respectively, obtained at 2 minute time point obtained in theStain Perception Measurement under TEST METHODS above.

Example 7: Fiber-Fiber Distance

Fiber to fiber distances in z-direction in nonwoven layers of samples 10and 11 were measured according to Fiber-Fiber Distance Measurementdescribed under TEST METHODS above and results are indicated in Table 6.

TABLE 6 Sample 10 Sample 11 Fiber-Fiber distance in 108 48 nonwovenlayer (μm)

Example 8: Softness

Softness of samples 10 and 12 was measured using product characteristicsincluding those specified in Table 7 with 17 sensory panels extensivelytrained to rate the intensity of the discrete product characteristics ona 0-100 using all their senses. Data is reported as means for the entiregroup. Results are shown in Table 7 below. Sample 10 with a 12 gsm filmlayer skin-facing surface shows favorable scores in all four itemscompared to sample 12, a 22.4 gsm film layer in a skin-facing surface.

TABLE 7 Sample 2 Comparative Sample 3 Fuzzy Feel 10.2 1.7 Plastic Feel35.5 58.6 Cottony Feel 31.1 15.7 Rough Feel 22.0 46.1All attributes were assessed on a 0-100 pt scale for intensity anchoredas 0=none, 50=moderate, 100=extremely high.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A laminate web comprising a polymer film layercomprising polymer film, a nonwoven layer comprising a nonwoven web, afirst side comprising the polymer film, and a second side opposed to thefirst side, the second side comprising the nonwoven web, wherein thelaminate web further comprises: a) an array of first elements extendingfrom the polymer film, wherein the array of first elements comprisesapertures, wherein the array of first elements comprises a firstplurality of first elements, a second plurality of first elements, and athird plurality of first elements, b) a plurality of second elementsformed downwardly from the first side of the laminate web, each of theplurality of second elements being longitudinally and laterally spacedfrom one another, wherein the second elements are recesses, and c) aland area defined between and surrounding the plurality of secondelements, the land area comprising the first plurality of firstelements, and the land area being disposed in a first region of thelaminate web, wherein the recesses extend below the second side of thelaminate web in the first region, so that a bottom area of each of therecesses is below the second side of the laminate web comprising theland area, wherein each of the recesses comprises a sloped side wallextending to a distal portion that at least partially defines the bottomarea, wherein the sloped side wall comprises the second plurality offirst elements and the distal portion comprises the third plurality offirst elements, wherein the first plurality of first elements has agreater number of first elements than the second plurality of firstelements, wherein at least one of the first elements in the thirdplurality of first elements is larger than at least one of the firstelements in the second plurality of first elements, and wherein at leastone first element in each of the recesses has an open distal end largerthan at least one of the open distal ends of the first elements in anadjacent portion of the land area, wherein the open distal end of the atleast one first element in at least some of the recesses is at least twotimes larger.
 2. The laminate web according to claim 1, wherein thebottom area each of the recesses is at least about 50 um below thesecond side of the laminate web.
 3. The laminate web according to claim1, wherein the bottom area is from about 0.05 mm² to about 15 mm². 4.The laminate web according to claim 1, wherein the first elements areextending upwardly away from the nonwoven layer.
 5. The laminate webaccording to claim 1, wherein each of the recesses has a shape in a planview selected from the group consisting of a circle, oval, quadrilateralshape, hexagonal shape, octagonal, and combinations thereof.
 6. Thelaminate web according to claim 1, wherein each of the recesses has alozenge shape in a plan view.
 7. The laminate web according to claim 1,wherein the laminate web further comprises a plurality of third elementsselected from the group consisting of apertures different from theapertures of the first elements, embossments different from the recessesof the second elements, and a combination thereof.
 8. The laminate webaccording to claim 1, wherein the polymer film layer has higherstretchability than the nonwoven layer.
 9. The laminate web according toclaim 1, wherein the laminate web comprises the recesses with a recessdensity of from about 10 to about 50 recesses/cm² web.
 10. An absorbentarticle comprising a liquid permeable topsheet, a liquid impermeablebacksheet, and an absorbent core disposed between the topsheet and thebacksheet, wherein the topsheet comprises the laminate web according toclaim
 1. 11. The absorbent article according to claim 10, wherein thepolymer film layer of the laminate web is an outer most layer in theabsorbent article facing the skin of a wearer.
 12. The absorbent articleaccording to claim 10, wherein the nonwoven layer of the laminate web isan outer most layer in the absorbent article facing the skin of awearer.